Flexible system of small-scale linear parabolic solar concentrators for power generation and dehydration

ABSTRACT

The invention relates to a solar energy collection system that uses linear parabolic concentrators designed on a small scale and with a modular configuration that allows optimum usage of solar collection surface area in places such as the roofs or flat roofs of factories or shops where space is generally small or irregular. The solar collector is coupled in rows actuated by a fully autonomous system for electronically controlling solar tracking, the operation of which is based on an algorithm programmed in a microcontroller. An autonomous solar tracking system can efficiently control two parallel rows with a pre-defined number of solar concentrators, as well as automatically detecting the presence of impurities on a reflecting radiation surface for the maintenance thereof. The thermal energy produced is harnessed by a heat exchanger, the operation of which is based on conduction, convection and radiation for dehydration uses.

OBJECT OF THE INVENTION

Energy is one foundation in developed countries, and factories and stores in industrialized societies typically generate energy based on fossil fuels to obtain process heat. Diesel, LPG and natural gas are fuels used in these sectors where companies shall withstand their constant increases and cost volatility.

There are technologies in marketplace for solar energy application within a generation range from 50 to 90° C. with flat-type collectors and vacuum pipes, commonly used for household water heating use. Within a range from 300 to 750° C. or above, solar concentration technologies commonly used for electric power generation through thermal solar plants may be found, located in large and open spaces such as desserts. Within a range from 100 to 300° C. there are limited options for solar energy supply, and this range is typically used by factories or stores in processes such as water heating, steam generation, product and foodstuff dehydration and the like. Said temperature range may be reached by parabolic-linear concentrators which collect solar energy transforming it into useful heat. A special interest application at reported temperature levels (100-300° C.) is solar energy foodstuff dehydration, allowing conservation of vegetables, fruits, grains and other crops in a practical and economical way by not using fossil fuels thereto.

The invention disclosed in this document is a solar concentrator with flexible and modular features allowing easy installation, better usage of available solar collection area, lower costs in logistics and transportation and great flexibility to be installed on roofs or factory and shop areas at ground level. Combined with above mentioned invention, the invention of a highly efficient system for product dehydration provided by application of solar thermal energy and collected by a small scale linear parabolic concentrator is also introduced such as that above disclosed, which transfers energy by three heat transfer modes: convection, radiation and conduction towards a dehydration exchanger. The dehydration system has a high operation temperature and industrial scale production capacity, which is not currently commercially offered by current solar energy products.

BACKGROUND OF INVENTION

There are currently parabolic-linear concentrators for a number of applications in the market, with an operation based on a linear parabolic mirror moving along a shift axis, tracking the sun path during the day in a North-South or East-West orientation. A thermal receiver is coupled to the concentrator focal line which is typically a tubular element manufactured of coated stainless steel with a selective surface for direct normal irradiation, this receiver pipe is further coated with a glass concentric cylinder which prevents losses by thermal convection. Said collectors are installed in row and column arrangements depending on the power calculated for the generation plant. A high thermal transfer fluid or water is circulated within the receiver, which absorbs the heat power coming from the sun which is reflected by the parabolic mirror, thus transporting energy to a conventional thermodynamic cycle for applications such as electric power generation, process heat, refrigeration or a combination of several processes. The cycle has elements such as hydraulic pumps, turbines, condensers, cooling towers and other devices.

There are currently solar concentration systems for thermal energy generation with process heat applications, however, their use is often restricted for developing countries or for those not having government incentives in terms of renewable energies, which in turn leads to high installation and commissioning costs for the companies. In addition to above problems, manufacturers of these systems impose restrictive demands such as: high costs of engineering, supervision, logistics and maintenance. Quite important to note is that solar concentration technologies currently in the market do not show sufficient flexibility and adaptability in their energy production capacities for a wide range of user requirements; this means that finding a technology with all its features (collector, solar tracking controller and thermodynamic elements) easily adapted to the roofs or installation spaces and to energy demand of several users is complicated. One important limitation regarding to currently available parabolic-linear mirror concentrator systems is that most of them are difficult to install in reduced spaces such as flat-roofs in factories and stores. Usually, it is very common to find installation spaces with little adapted orientations for solar path in small and medium-size companies, and irregularities which make even more difficult to install equipment and a better usage of installation area due to a lack of flexibility and modularity of current technologies in marketplace having already defined physical measures.

Based on above paragraph explanation, it has been identified a need in factories and stores to have a reliable, flexible, modular and low-cost solution for thermal energy generation useful in processes, without suffering the constant cost fluctuation of fossil fuels.

One application of special interest is food product dehydration based on solar energy, allowing conservation of vegetable, fruit, coffee and many other types of crops in a practical and economical way.

Solar concentration technologies have a number of applications due to their efficiency at a high temperature range, where conventional flat collectors do not achieve a proper performance. There are dehydration systems currently using solar energy, which are classified in two types: passive, operating by natural circulation or convection and active, using forced convection for functioning. Both technologies offer a sustainable, hygienic alternative and with sanitary conditions under international standards for food processing, without representing a high cost compared to fossil fuel systems. However, said systems do not have sufficient dehydration capacity for large industrial stocks and their operative temperature hardly reaches 100° C., which results in a lower product dehydration speed and therefore, lower production rates. Coupling of a parabolic-linear mirror concentrator system, suitable for industry installation, for industrial dehydration processes is a feasible solution by supplying suitable temperature ranges for this process by solar energy. It is worth to mention that most of the product dehydration systems, whether by solar energy or fossil fuels, transfer heat to the products to be dehydrated by natural or forced convection, which is not an efficient method of thermal energy use.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is an isometric view of a linear parabolic solar concentrator 1, for energy and dehydration generation, comprising a reflective surface 2, a reflecting mirror support structure 19, an electronic control solar tracking system 3, an electromechanical actuator 5, a solar position sensor 4, rear support arcs 7, support masts for each module 10 and a solar irradiation receiver 6.

FIG. 2 is a rear view of the parabolic solar concentrator 1, where stress support traverse bars 11 and stiffness rear ribs 7 are shown.

FIG. 3 shows a side view of the linear parabolic solar concentrator.

FIG. 4 shows a detailed view of the reflective surface 2, sectioned in equal and symmetrical parts 20 in addition to a support rear structure 19 of the reflective surface.

FIG. 5 shows an isometric view of the linear parabolic solar concentrator structural elements consisting of parabolic curve stiffness arcs 7 and transverse stress supports 11.

FIG. 6 shows a detailed view of the structural element assembly components consisting of threaded bolts in both sides 13 and inner thread nuts 12.

FIG. 7 shows an isometric view of a row of serial assembled collectors 15 coupled by spin pivot bearings 9 and alignment pins 18.

FIG. 8 is a view of several collector rows 15 installed on a building roof 47, the rows consisting of full modules 1 and halves of each module 14.

FIG. 9 shows an upper view of the collector rows 15 installed on a building roof or flat roof 17 and surrounded by safety walls 16 used in construction.

FIG. 10 is an isometric view of a half-section of the linear parabolic collector.

FIG. 11 is a sectioned front view of a tunnel-type modular solar dehydrator 22, whereby a thermal fluid is introduced in a zigzag inlet piping 23, having a fluid outlet 33, a bottom 24 and an upper plate 25 each other transmitting thermal energy by heat conductor bars 27 towards an assorted nature product 34 and heat is insulated from outside by an inner protective surface 32 in contact with a thermal insulator 26 and an outer surface 33. Ventilators 30 are also shown as thermal convection actuators, thermoelectric cells as heat-to-electricity transducers 29 and heat sinks 31.

FIG. 12 is another section view of the tunnel-type solar dehydrator 22, with schematic drawings of the heat flows involved in product dehydration. Convection heat flow 37, radiation between plates 38, radiation from conductor bars 27 towards surroundings 39 and a heat inlet 35 together with its respective outlet 36 are shown.

FIG. 13 is a scheme of a thermodynamic circuit comprising a solar collector field 40 in rows and columns coupled to a backup heater 41 using any fossil fuel, a tunnel-type solar dehydrator 22, a condenser 43 and a recycle pump 42. A low-temperature thermal transfer fluid 44 is circulated through the components, providing high temperature heat 45 within the dehydrator 22.

FIG. 14 shows an arrangement wherein a boiler or fuel heater 41 functions as pre-heated fluid superheater by solar collector field 41.

FIG. 15 shows a component assembly for the solar tracking actuator system 51, where an electronic control module 3 may be seen which receives luminosity signals proceeding from a photoelectric sensor 4. The electronic control module 3 calculates the required positions of the electromechanical actuator 5 and sends control signals to this last element, therefore the joint mechanism of serial solar collectors (FIG. 7) may rotate by making a solar tracking over a horizontal rotation axis.

FIG. 16 shows a flow diagram of the algorithm 52 used for solar tracking electronic control.

FIG. 17 shows an arrangement of two solar concentrator rows 61 together with a solar tracking electronic control central module 3.

FIG. 18 shows an arrangement of two detection elements or temperature sensors which may be also solar luminosity sensors 65 and 66, detecting light intensity or energy amount incident on its surface and sending a notice signal to the user, so that he may provide a proper cleaning to the reflective surface 2 of the solar concentrator.

DETAILED DESCRIPTION OF THE INVENTION Linear Parabolic Solar Concentrator

The present invention consists of a small scale parabolic-linear solar concentrator. Its size and design have been created to be used by a number of factories and stores, providing the easiness to be installed on roofs or company's open areas, allowing adaptability to energy user requirements because of an integral and modular arrangement of the solar tracking collector-controller. Moreover, its flexible design provides a possibility of more usage of installation area thus providing a higher solar energy collection in reduced spaces, without representing a risk for the users due to inclement weather which may be present at the location.

The solar collector performance is based on the parabolic curve principle:

$y = \frac{x^{2}}{4\; f}$

wherein:

f=Parabolic curve focus point.

x=Horizontal distance from center.

y=Vertical distance.

The parabolic curve is extruded to create a channel or concave shape surface sectioned in symmetrical panels 20, assembled by aluminum or steel metallic profiles (but not limited to these materials) which limit the panel outline and comprise structural crossbars providing higher stiffness to each piece 19. A reflective surface based on aluminum sheet (not restricted to this material) 2 with a highly reflective sunlight mirrored finish is adhered to the panel frame by fastening elements such as screws, rivets or special adhesives. A suitable reflective material consists of a mirrored-finishing aluminum sheet coated with an anodized surface suitable to support weather exposure during extended periods. It is also possible to use a polymeric film reflective material with silver coating, laminated with pressure-sensitive adhesive over a metallic or plastic sheet. There is also a possibility to use an acrylic-base reflective material coated with a reflective coating, which allows to be molded according to the intended geometric shape.

In order for the concentrator to be capable of supporting wind loads which have an impact on its surface without showing any deformation, the concentrator has elements providing stiffness upon compression and further upon stress being present during weather phenomena, then a curved-rib base structure 7 is included, providing high compressive strength and parabolic curve mechanical expansion and attached each other by several transverse tubular elements 11, providing excellent tensile strength and transverse compression to the solar collector. Crossbars 11 are fastened with ribs 7 by two-side threaded nuts 12 and screws 13 for easy assembly.

One of the main properties of the solar concentrator is its modularity for system design and installation with a number of power generation capacities, serially coupled, where one to eight modules in a row 15 may be arranged attached each other by rounded spin axes supported over bearings 9 allowing solar tracking spin motion throughout a day in a North-South or East-West axis. A power transmission comprising a direct current electric motor (not restricted to this type) 5 coupled to an endless screw arrangement and a helical gear allows torque increase and motion interlock when the motor is not energized. The transmission system also includes a set of coupled pinions 8 increasing the transmission ratio, thus achieving a slower and more accurate solar tracking motion.

A receiver element 6 which collects parabolic mirror thermal energy is positioned in the parabolic curve focal point, which is capable of absorbing said energy by a copper or stainless steel cylindrical pipe (not limited to these materials) with a highly absorbent selective surface for solar irradiation; a second borosilicate or glass pipe is concentrically arranged to the metallic pipe with a high transmissivity index and low reflectivity to solar radiation, thus lowering those convection losses caused by wind.

Solar Tracking Electronic Control System.

A smart electronic control unit 3 actuates an electric motor 5 (this unit being expansible to a second motor) and achieves keeping the solar concentrator orientation throughout the day towards the maximum possible irradiation amount. The solar monitoring or tracking system operates on alternating current basis at 120V (not restricted to this voltage), which may be directly supplied by the utility company or by any solar to electric power conversion system such as photovoltaic panels. The electronic controller uses a position control algorithm 50 programmed in a semiconductor element called microcontroller, which is capable of performing calculations to compensate system position based on voltage difference readings, provided by the pyramidal-array photoelectric sensor 4. The algorithm has been specially conceived for functioning with the disclosed mechanical system and is the element which provides intelligence and solar energy collection autonomy to the system, on the opposite side, the mechanical system is useless without this control algorithm. The tracking system 3 together with its components; photoelectric sensor 4, control card with microcontroller and supply and measurement connections comprise a single component integrating a solar tracking module 51 which is easy to install, calibrate and arrange in a small size parabolic-linear solar collector 1 (not restricted to this type of collector, dish-type solar collectors or photovoltaic systems may be adapted among applications requiring a high accuracy and automatic active solar monitoring).

The solar tracking electronic control smart unit 3 may be installed in a two-row solar collector arrangement 61 as shown in FIG. 17, the control module 3 has the capacity to receive signals proceeding from a row of up to ten solar concentrators 62 and another equally in parallel 63, each with a solar luminosity sensor 4 indicating an ideal position in a determined time of the day for each of the rows. Once the solar tracking module 3 calculates the ideal position of each of the two collector rows, transmits electric control signals to the electromechanical actuators 5 located in the motion transmission system 8 of each collector row. This dual arrangement of solar tracking control allows reducing system's manufacturing costs and cutting installation and commissioning time for the solar concentration system.

The solar tracking control system includes two temperature or luminosity sensors 65 and 66, located on the solar radiation receiver 6, these sensors detect a temperature or light intensity difference and they send signals as a second feedback towards the solar tracking electronic control 3. The sensors located in the solar receiver 65 and 66 also act as soil or impurity detection instruments on the reflective surface 2 of the linear parabolic concentrator 1, this function allows correct detection when system demands maintenance and cleaning on the reflective surface 2 and thus system performance is optimal during useful life with a lower maintenance cost.

Solar Tracking Electronic Control Algorithm

The system starts in a rest state performing solar luminosity measurements 53. When the system detects that light intensity is sufficient to start conducting an alignment routine 54 it then goes into a first alignment stage, or the solar position control 55 is turned on. Once that the system is aligned by carrying the position error at zero level, the algorithm enters into a continuous alignment error measurement cycle 57 and controls the solar collector position throughout the day. As sun's apparent motion reaches sunset and nighttime luminosity level 59 is detected, the algorithm leaves the control cycle and enters into a return status to the solar collector 60 initial position where kept ready and in a rest state 53 starting again the following day with the control routine 52.

Solar Dehydration System

The solar dehydration system consists of an exchanger operating in three available heat transfer modes: conduction, convection and radiation. Said exchanger consists of a thermal chamber manufactured with metallic materials 32 (not limited to these materials) and coated with a refractory or insulating material 26 preventing heat losses outside. An arrangement of zigzag piping is located within this chamber 28 said piping made of copper or stainless steel (not restricted to this material) wherein steam or a high thermal transfer oil is circulated, the piping arrangement conducts heat to a metallic sheet made of copper, carbon steel or stainless steel (not limited to these materials) 24, which in turn is interconnected to a parallel plate 25 located in the opposite side of the exchanger by a high thermal transfer material such as copper, steel or graphite bars (not limited to these materials) 27. The dehydrator or exchanger has also ventilators 30 producing a forced outside-to-inside air convection, causing in this way a hot air regular flow 37 with an outlet in system's upper section. The operation principle of this dehydrator consists of heat transfer by thermal conduction from piping to parallel plates, which in turn transfer heat to the product to be dehydrated by convection produced by ventilators 37, and radiation heat transfer between the two plates 38 caused by a temperature difference among them and also radiation between the conductor bars and their surroundings 39. The use of electric power is required in order to lead to a forced convection with the ventilators, which often is not easily available in and agricultural environment, then the system has thermoelectric cells 29 located on the lower temperature plate side which in turn is connected to the outer side by heat sinks 31. Cell performance consists of absorbing the heat from said plate, transforming it into electric power due to a temperature difference between dehydrator inner and outer sides, so that electric power is used and ventilators which produce forced convection are actuated. The dehydration system is modular and may be serially interconnected with identical systems until reaching the required thermal capacity for dehydration.

In order to achieve high temperatures within the dehydrator chamber, this is interconnected with an arrangement of solar concentrators 40 which heat the thermal fluid and optionally further to a heating backup system with any fossil fuel 41 such as diesel, LPG, natural gas, and the like, thus supplying sufficient energy according to the required operative conditions. 

1.-15. (canceled)
 16. A linear parabolic solar concentrator flexible system for power generation and dehydration comprising at least one linear parabolic solar concentrator comprising the following elements: a) a surface with a parabolic channel shape sectioned in at least two equivalent size symmetric panels or sections, individually shaping a support frame made of reflective materials; b) a mirror mounted on each of the panels and fastened by a plurality of fastening elements; c) at least two curve support arcs providing stiffness to the reflective parabolic surface upon wind impact, and longitudinally located and distributed on the solar collector rear section; d) a plurality of cross tubular elements, each other joined with the support arcs by fastening means, said tubular elements provide higher tensile strength to keep the parabolic surface geometry firm; e) a solar concentrated radiation receiver element shaped by a cylindrical pipe coated with a selective surface to solar radiation and protected from convection losses by a concentric and transparent pipe; f) a heat exchanger for product dehydration consisting of a thermal chamber insulated from environment, a heat inlet through a high temperature fluid with its respective outlet, and an arrangement of ventilators and thermoelectric cells producing a constant air flow within the chamber; and g) a solar tracking electronic control module based on photovoltaic or phototransistor cells having a solar tracking algorithm embedded in a microprocessor or microcontroller, and wherein the system is coupled with an electromechanical actuator keeping the collector position towards the sun rising angle at any time.
 17. The system according to claim 16, wherein the fastening means comprise screws and threaded bars.
 18. The system according to claim 16, wherein the concentric and transparent pipe is made of borosilicate or glass.
 19. The system according to claim 16, which allows serial coupling of a plurality of modules, forming a concentrator row in a North-South or East-West orientation, which each other are coupled by bearing supported axes providing a 180° angular motion and thus forming a row arrangement allowing flexible scale up/down of the solar energy collection capacity.
 20. The system according to claim 16, which comprises assembly means allowing housing of a number of solar collector geometries.
 21. The system according to claim 19, consisting of a mechanical transmission system comprising: a direct or continuous current electric motor with endless screw reduction and helical gear; and a set of pinions and chain as transmission elements to the angular motion input actuator.
 22. The system according to claim 21, further comprising means allowing an angular motion and an automatic blockage when the direct or continuous current motor is not powered.
 23. The system according to claim 16, which is coupled to an electronic control module for solar tracking comprising: a) a solar irradiation sensor in a pyramid-type arrangement with at least two photocells or phototransistors located one after another, measuring a voltage differential signal and determining the direction and amount of solar collector motion; b) a photocell capable of detecting the solar radiation level depending on day's hour; c) an electronic control device based on a microprocessor or microcontroller and power elements calculating the control signals sent to the angular motion electric actuator; d) an algorithm embedded in the electronic control device governing the solar tracking control and electronic system performance.
 24. The system according to claim 23, wherein the solar irradiation sensor is expanded to a second motion axis by the use of two more cells in the same arrangement.
 25. The system according to claim 16, replicated an undefined number of times in row and column arrangements, and interconnected with a heat exchanger allowing heat transfer by forced convection for product dehydration.
 26. The system according to claim 25, interconnected to a parabolic solar concentrator arrangement collecting solar energy at high temperature and transferred to the dehydrator thermal chamber by steam or a high thermal transfer fluid, a recycle pump and a condenser.
 27. The system according to claim 25, which is interconnected to a parabolic solar concentrator arrangement and further to a thermal backup system based on fossil fuels such as a boiler or electric heater.
 28. The system according to claim 25, which is mechanically connected to several equivalent serial modules forming a longer dehydration tunnel with higher dehydration power capacity.
 29. The system according to claim 27, which includes a product automatic transportation system, allowing a higher moisture removal.
 30. The system according to claim 16, which is installed and coupled with a plurality of solar concentrators in two parallel rows, wherein each of the rows is individually controlled by a single solar tracking electronic control module, detecting signals proceeding from a solar luminosity sensor located at each of the two rows and sending control signals to the two electromechanical actuators controlling the solar tracking angular motion of each row.
 31. The system according to claim 16, which is coupled to a reflectivity sensor located in the solar radiation receiver, said sensor consisting of two sensitive elements forming a differential reference and functioning on a heat or sun light basis reflected by the solar concentrator reflective surface, the sensor has the capability to detect the soiling level or impurity amount such as dust or soil on the reflective surface and to send a notice signal to the user through the electronic control module so that the required cleaning and maintenance may be conducted.
 32. The system according to claim 31, wherein the temperature or solar luminosity sensors transmit signals used as feedback for the solar position control system, determining the amount of light or energy at any time by means of the temperature in this receiver as a second reference of the collector's ideal position in respect to solar radiation impacting on its surface.
 33. A high efficiency heat exchanger for product dehydration applications based on conduction, convection and radiation as main heat transfer mechanisms, comprising: a) a chamber which transfers thermal energy proceeding from a solar concentrator system coupled to a backup system based on fossil fuels, said thermal energy is delivered to a product to remove a certain moisture percentage in its physical composition; b) a thermal insulator, which does not allow heat transfer from chamber inner side to outer side; c) a coiled piping carrying inside a high thermal transfer fluid towards the inner part of the thermal chamber; d) an arrangement of two parallel metallic plates each other transferring thermal energy, from one high temperature end connected to the coil to the low temperature plate located on the opposite side, said plates transferring thermal energy to the product to be dehydrated and each other by a thermal radiation mechanism; e) a high thermal transfer bar arrangement interconnecting the two parallel plates each other, thus achieving a conduction heat transfer therebetween and further transferring the heat from within by radiation towards the product and the walls within the chamber; f) a ventilator arrangement operating with electric power and which when turned on causes an air flow from dehydrator outer side to thermal chamber inner side, thus generating heat transfer by forced convection to the product to be dehydrated; g) an arrangement of thermoelectric cells connected to the exchanger cold plate and heat sinks in contact with dehydrator outer surface, thus causing a temperature difference in thermoelectric cells and a heat flow which in turn generates electric power, said electric power with the purpose of actuating the ventilators thus making the system more efficient; and h) a sensor arrangement located inside the thermal chamber measuring the moisture current amount and interconnected to an electronic control system regulating the ventilator rotation speed, thus causing a moisture control based on the convection heat transfer rate to the product to be dehydrated. 